Category Archives: Parts

Lithium Starter Battery

Doesn’t look too bad…

I was unfortunate enough to have the battery fail in my car recently. It had given an indication that it wasn’t well, with a few failed starts & stalled cranks. But it would start the engine and when I checked the battery it tested fine, the alternator was charging correctly and it only accepted a small top up charge. It wasn’t till I had to isolate the battery while doing other work that I noticed the corrosion above. Then…

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It Takes A Lot of Work…

It takes a lot of work to get to the stage of putting a bike project back together. Media blasting, sanding, de-greasing & ordering new parts. It can be tempting to rush but taking care in assembly will make sure everything works. It took a few trial assemblies to get the shims right on the QA-50 engine & transmission. Everything was fitting together nicely with minimal end-play. Then this happened…

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Quiet On the Blog but…

It may be quiet on the blog

Quiet on the blog but it has been busy in the workshop with a number of projects progressing. My VSCCS application has been approved in NSW and I am just waiting on a response from the WA Department of Transport. And the picture? Well one of the projects in progress is a rebuild of a 1974 Honda QA50. This is the engine casing after a quick bead blasting.

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Motard Complete & Tested

As mentioned previously on this blog, this is a motard style conversion of a Honda CRM 250 using a 2007 model Aprilia RS-125 wheels, discs and front brake caliper.

A custom bracket was designed in Solidworks to adapt the radially mounted caliper to the original brake caliper mounting holes. Designing in 3D allowed the part to be simulated (FEA) with heavy braking loads and calculate the factor of safety, stress, strain and distortion.

One of the advantages of using the Aprilia wheels over the popular wire spoke wheels is that they incorporate a cush-drive to reduce driveline vibrations. Continue reading Motard Complete & Tested

APRILIA RS-125 CALIPER ON HONDA CRM-250

The APRILIA RS-125 caliper has finally been installed on the Honda CRM-250. The brake system has been bled with a quality DOT-4 brake fluid. It now has a solid feel (though there is some sponginess due to brake hose expansion – this may be replaced with a braided line) and no leeks in the system. So far low-speed testing has been carried out with further testing to come.

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Replacing Obsolete Parts

This was a practical application of using 3D-printing to fabricate replacements for obsolete parts. The center caps for Holden Commodores with steel rims is a good addition to crate a tidy standard looking vehicle. These parts were commonly available and many were probably thrown away when steel rims were upgraded to alloy wheels but now a set can be from $100 – $180. Continue reading Replacing Obsolete Parts